Solar Installation Safety Manual

What Should a Solar Installation Safety Manual Include?

The contents of a Solar Installation Safety Manual should reflect the solar contractor’s actual operations.

A residential rooftop installer may have different hazards than a contractor constructing a utility-scale solar facility. Commercial rooftop installations may involve cranes, material staging, roof openings, electrical rooms, and coordination with building owners, while ground-mounted projects may involve excavation, pile installation, underground electrical systems, and heavy equipment.

The manual should begin with the company’s Core Construction Safety Programs and then include additional programs applicable to the company’s solar installation activities.

Core Safety Programs for Solar Contractors

A comprehensive Solar Installation Safety Manual may include core programs addressing:

• Accident and Incident Investigation.
• Emergency Action Plan.
• Fire Prevention.
• First Aid.
• Hand and Power Tool Safety.
• Hazard Communication.
• Housekeeping.
• Job Safety Analysis (JSA/JHA).
• Manual Lifting and Material Handling.
• Personal Protective Equipment.
• Slips, Trips and Falls.
• Walking-Working Surfaces.
• Electrical Safety.
• Ladder and Stairway Safety.

The manual should also establish responsibilities for management, supervisors, employees, competent and qualified persons, hazard identification, workplace inspections, safety training, hazard correction, incident reporting, recordkeeping, and periodic review of the company’s safety programs.

Solar Installation Safety

Solar installation combines several significant construction hazards within the same operation.

Depending on the project, work may involve:

• Rooftop access.
• Fall exposures.
• Photovoltaic electrical systems.
• Panel and racking installation.
• Ladders.
• Cranes and material hoists.
• Aerial lifts.
• Hand and power tools.
• Electrical equipment.
• Trenching and underground utilities.
• Heavy equipment.
• Battery energy storage.
• Outdoor environmental exposure.

Work should be planned before installation begins so the hazards associated with the site, system, equipment, and installation method can be identified and controlled.

Pre-Job Hazard Assessment and JSA

A pre-job hazard assessment or Job Safety Analysis can help identify hazards before solar installation begins.

The assessment should consider:

• Roof condition and configuration.
• Roof edges and openings.
• Skylights.
• Access and egress.
• Electrical systems.
• Overhead power lines.
• Panel and material handling.
• Weather.
• Tools and equipment.
• Crane or hoist operations.
• Other contractors.
• Public or customer exposure.
• Ground conditions.
• Excavations.
• Emergency access.

The assessment should be reviewed when site conditions, work activities, equipment, or other hazards change.

Rooftop Solar Installation

Rooftop solar installation can expose employees to falls from roof edges, skylights, roof openings, ladders, and other elevated surfaces.

Before rooftop work begins, the contractor should evaluate:

• Roof height.
• Roof slope.
• Roof condition.
• Structural condition where relevant.
• Roof edges.
• Skylights and openings.
• Access points.
• Fall-protection methods.
• Material staging.
• Electrical hazards.
• Weather.
• Emergency and rescue considerations.

Solar panels, racking, tools, cords, and other materials should be positioned so they do not create unnecessary trip hazards or obstruct safe access.

Fall Protection

Fall protection is one of the most important components of solar installation safety.

Employees performing construction work exposed to applicable fall hazards should be protected using methods permitted by OSHA and appropriate for the work.

Depending on the operation, fall-protection systems may include:

• Guardrail systems.
• Safety-net systems.
• Personal fall-arrest systems.
• Covers.
• Other permitted fall-protection methods.

Employees should be trained to recognize fall hazards and properly inspect, use, and maintain the fall-protection equipment required for their work.

Roof Edges, Skylights and Openings

Roof edges, skylights, roof hatches, and other openings can create serious fall hazards during solar installation.

As solar panels and materials are placed on a roof, available walking and working space may become restricted.

Skylights and openings should be protected as required using appropriate guarding, covers, fall-protection systems, or other permitted methods.

Employees should not assume that a skylight can support their weight.

Ladder Safety and Roof Access

Ladders are commonly used to access residential and commercial roofs.

Ladders should be:

• Appropriate for the task.
• Inspected before use as required.
• Positioned on stable surfaces.
• Properly angled where applicable.
• Secured when necessary.
• Protected from traffic and other hazards.
• Kept clear of electrical hazards.

Employees should maintain appropriate contact while climbing and should not climb ladders while carrying solar panels or other loads that prevent safe climbing.

Mechanical lifting equipment should be used where practical to move panels and other bulky materials to elevated work areas.

Solar Panel Lifting and Material Handling

Solar panels can be large, awkward, fragile, and affected by wind.

Material-handling procedures should address:

• Panel weight and dimensions.
• Manual lifting.
• Team lifting.
• Mechanical lifting.
• Hoists.
• Cranes.
• Wind.
• Roof access.
• Panel staging.
• Sharp edges.
• Pinch points.
• Secure storage.

Panels should be staged so they do not obstruct access routes or create fall, trip, or falling-object hazards.

Falling Objects

Tools, fasteners, racking components, panels, and other materials can fall from rooftops and elevated work areas.

Controls may include:

• Restricted areas.
• Barricades.
• Tool control.
• Material securement.
• Controlled access.
• Appropriate storage.
• Communication with employees below.

Employees and members of the public should be kept clear of areas where falling objects could create a hazard.

Electrical Safety

Electrical hazards are a defining feature of solar installation.

Employees may encounter photovoltaic modules, conductors, inverters, disconnects, electrical panels, batteries, utility systems, temporary power, and existing building electrical equipment.

Electrical procedures should address as applicable:

• Employee qualification.
• Energized components.
• De-energization.
• Testing.
• Electrical PPE.
• Temporary electrical systems.
• Grounding.
• GFCI protection.
• Tools and test equipment.
• Electrical panels.
• Overhead power lines.
• Grid interconnection.

Only appropriately qualified employees should perform electrical work requiring such qualification.

Photovoltaic Electrical Hazards

Photovoltaic systems present unique electrical considerations because PV modules can produce electrical energy when exposed to light.

Solar installers should understand that shutting off a disconnect may not eliminate every source of electrical energy within a PV system.

Work planning should consider:

• Module output.
• DC conductors.
• Combiner equipment.
• Inverters.
• Disconnects.
• AC systems.
• Stored energy.
• Backfeed.
• Utility sources.
• Testing and verification.

Employees should follow applicable electrical safe-work practices and manufacturer instructions.

De-Energizing and Hazardous Energy Control

Solar installation, commissioning, troubleshooting, service, and maintenance may require employees to control electrical or other hazardous energy.

Where applicable, procedures should address:

• Identification of energy sources.
• Shutdown.
• Isolation.
• Lockout/tagout.
• Stored energy.
• Verification.
• Authorized employees.
• Restoration to service.

Employees should not assume that equipment is de-energized solely because a switch or disconnect has been operated.

Arc Flash and Electrical PPE

Certain solar electrical work may expose qualified employees to arc-flash or other electrical hazards.

Where applicable, the contractor should evaluate the electrical hazards and establish appropriate safe-work practices and PPE requirements.

Electrical protective equipment may include:

• Voltage-rated gloves.
• Eye and face protection.
• Arc-rated clothing.
• Insulating equipment.
• Other electrical protective equipment appropriate to the hazard.

Electrical PPE should be inspected, maintained, and tested as required.

Temporary Electrical Systems

Construction of solar projects may involve temporary electrical power, extension cords, portable tools, generators, and temporary lighting.

Procedures should address applicable requirements for:

• GFCI protection.
• Extension cords.
• Portable electrical equipment.
• Generators.
• Grounding.
• Wet locations.
• Equipment inspection.
• Damaged cords and equipment.

Defective electrical equipment should be removed from service.

Grid Interconnection

Solar contractors connecting systems to electrical distribution systems may encounter additional electrical hazards and requirements.

Work should be coordinated with the utility or system owner as necessary.

Procedures may need to address:

• Utility authorization.
• Disconnects.
• System isolation.
• Backfeed.
• Energization.
• Testing.
• Qualified employees.
• Electrical PPE.
• Communication.

The standards applicable to a solar installation depend on the nature of the work and electrical system involved.

Overhead Power Lines

Solar installers may use ladders, cranes, hoists, aerial lifts, long materials, and other equipment near overhead electrical lines.

Power-line hazards should be identified before work begins.

Employees should maintain applicable clearances and use appropriate controls when equipment or materials could approach energized lines.

Overhead lines should be treated as energized unless their status has been appropriately verified.

Aerial and Boom Lifts

Aerial lifts may be used to access commercial roofs, elevated arrays, structural components, and other work areas.

Procedures should address:

• Pre-use inspections.
• Operator training.
• Fall protection.
• Ground conditions.
• Equipment positioning.
• Load limits.
• Overhead hazards.
• Electrical lines.
• Emergency lowering.

Employees should not exceed equipment capacity or use makeshift devices to obtain additional working height.

Scissor Lifts

Scissor lifts may be used for solar installations in warehouses, commercial buildings, parking structures, and other locations.

Procedures should address:

• Equipment inspection.
• Guardrails.
• Ground conditions.
• Overhead hazards.
• Electrical hazards.
• Travel.
• Load capacity.
• Manufacturer requirements.

Employees should keep both feet on the platform floor and should not climb or stand on guardrails.

Cranes, Hoists and Panel Lifting Equipment

Cranes, material hoists, ladder hoists, conveyors, and other lifting equipment may be used to move solar panels, racking, inverters, batteries, and other materials.

Applicable procedures should address:

• Equipment inspection.
• Operator qualification.
• Load capacity.
• Rigging.
• Ground conditions.
• Power-line hazards.
• Suspended loads.
• Employee positioning.
• Communication.

Employees should remain clear of suspended loads and equipment swing areas.

Rigging and Material Handling

Larger solar projects may require rigging for panel bundles, racking, electrical equipment, transformers, batteries, and other heavy components.

Rigging should be selected according to the load and inspected as required.

Employees should avoid positioning themselves beneath suspended loads or between loads and fixed objects.

Hand and Power Tools

Solar installers may use drills, impact drivers, saws, grinders, crimping tools, torque tools, and other hand and power tools.

Tools should be:

• Appropriate for the task.
• Inspected as necessary.
• Maintained in safe condition.
• Properly guarded.
• Used according to manufacturer instructions.

Employees should use appropriate eye, hand, hearing, and other protection based on the hazards involved.

Manual Material Handling

Solar installation may require employees to lift and position panels, racking, conduit, batteries, inverters, tools, and other materials.

Work should be planned to minimize unnecessary manual handling.

Employees should use:

• Mechanical assistance where practical.
• Team lifting.
• Proper lifting techniques.
• Appropriate carts and material-handling equipment.
• Safe staging practices.

Special consideration should be given to bulky objects that can catch wind or obstruct an employee’s view.

Heat Stress and Sun Exposure

Solar installers frequently work outdoors and on roofs where heat exposure can be substantial.

Heat-stress procedures should address:

• Drinking water.
• Rest periods.
• Shade or cooling.
• Acclimatization.
• Work scheduling.
• Employee monitoring.
• Recognition of heat illness.
• Emergency response.

Roof surfaces and solar components can increase radiant heat exposure.

Cold Stress and Severe Weather

Solar work may also expose employees to cold, wind, rain, lightning, snow, and other weather conditions.

Weather can significantly affect:

• Roof surfaces.
• Ladders.
• Fall protection.
• Crane operations.
• Panel handling.
• Aerial lifts.
• Excavations.
• Electrical work.

Work should be modified or suspended when weather conditions create unacceptable hazards.

Wind Hazards

Solar panels can act as large sails when carried or lifted in windy conditions.

Wind conditions should be evaluated before panels are manually handled, hoisted, or installed.

Employees should not attempt to control panels or other materials when wind conditions make handling unsafe.

Manufacturer limitations for cranes, aerial lifts, hoists, and other equipment should also be followed.

Residential Rooftop Solar

Residential solar installers may encounter:

• Steep or sloped roofs.
• Roof edges.
• Skylights.
• Ladders.
• Limited staging areas.
• Electrical service equipment.
• Overhead power lines.
• Customers and occupants.
• Landscaping and uneven ground.
• Panel lifting.
• Heat exposure.

Residential projects should be evaluated individually because roof configurations, electrical systems, access, and surrounding conditions vary substantially between properties.

Commercial Rooftop Solar

Commercial rooftop installations may involve larger arrays, flat or low-slope roofs, roof openings, skylights, mechanical equipment, cranes, hoists, electrical rooms, and other contractors.

Planning should address:

• Roof access.
• Fall protection.
• Material staging.
• Crane operations.
• Roof loading.
• Electrical systems.
• Other rooftop equipment.
• Building occupants.
• Emergency access.
• Coordination with the building owner or controlling contractor.

Ground-Mounted and Utility-Scale Solar

Ground-mounted and utility-scale solar construction can involve hazards substantially different from rooftop installation.

Operations may include:

• Site preparation.
• Grading.
• Excavation.
• Trenching.
• Underground electrical systems.
• Pile installation.
• Heavy equipment.
• Cranes and forklifts.
• Large-scale material handling.
• Electrical collection systems.
• Substations.
• Remote work locations.

The Solar Installation Safety Manual should include additional construction programs appropriate to these activities when the company performs utility-scale solar work.

Excavation and Trenching

Ground-mounted solar projects may require trenches for conduit, electrical systems, drainage, foundations, and other installations.

Where employees enter excavations, procedures should address applicable requirements for:

• Competent-person inspections.
• Soil classification.
• Protective systems.
• Access and egress.
• Underground utilities.
• Water accumulation.
• Spoil placement.
• Heavy equipment.
• Hazardous atmospheres.

Employees should not enter an excavation until required protective measures are established.

Underground Utilities

Before excavation, drilling, pile installation, or other ground-disturbing work begins, existing underground installations should be identified as required.

Potential utilities may include:

• Electrical systems.
• Gas.
• Water.
• Sewer.
• Telecommunications.
• Fuel systems.
• Other underground installations.

As work approaches known underground installations, their exact location should be determined using safe and acceptable means.

Pile Driving and Foundation Installation

Utility-scale solar arrays may use driven piles, ground screws, drilled foundations, or other support systems.

Where applicable, procedures should address:

• Pile-driving equipment.
• Heavy equipment.
• Equipment stability.
• Pinch points.
• Noise.
• Underground utilities.
• Overhead hazards.
• Employee positioning.
• Material handling.
• Equipment inspection.

Employees should remain outside hazardous equipment operating areas unless their presence is necessary and appropriately controlled.

Heavy Equipment and Mobile Equipment

Utility-scale solar projects may involve loaders, excavators, skid-steer loaders, telehandlers, forklifts, pile-driving equipment, trucks, and other mobile equipment.

Procedures should address:

• Operator authorization.
• Equipment inspection.
• Seat belts.
• Blind spots.
• Backing.
• Spotters.
• Pedestrian exposure.
• Travel routes.
• Ground conditions.
• Loading and unloading.

Employees on foot should remain clear of equipment operating zones whenever possible.

Battery Energy Storage Systems

Solar contractors may install or work around Battery Energy Storage Systems (BESS).

Where applicable, safety planning should consider:

• Electrical energy.
• Stored energy.
• Battery chemistry.
• Fire hazards.
• Thermal events.
• Electrical shock.
• Arc-flash hazards.
• Material handling.
• Ventilation.
• Manufacturer requirements.
• Emergency response.

Battery hazards vary significantly according to system design and chemistry. Procedures should therefore reflect the specific equipment being installed or serviced.

Hazard Communication

Solar installation may involve adhesives, sealants, cleaners, fuels, battery materials, coatings, and other chemicals.

Employees should have access to applicable Safety Data Sheets and receive required information and training concerning hazardous chemicals.

Containers should be appropriately labeled and chemicals stored and handled according to applicable requirements.

Fire Prevention

Solar installations may involve electrical equipment, batteries, hot work, combustible roofing materials, fuels, and other potential fire hazards.

Fire-prevention procedures should address as applicable:

• Ignition sources.
• Flammable and combustible materials.
• Fire extinguishers.
• Hot work.
• Battery systems.
• Housekeeping.
• Emergency notification.
• Access for emergency responders.

Employees should understand applicable emergency procedures before work begins.

Personal Protective Equipment

PPE should be selected according to the hazards associated with the solar installation.

Depending on the work, PPE may include:

• Hard hats.
• Safety glasses.
• Face shields.
• Work gloves.
• Protective footwear.
• High-visibility apparel.
• Hearing protection.
• Electrical protective equipment.
• Fall-protection equipment.
• Respiratory protection.

PPE should be inspected, maintained, and replaced as necessary.

Working Around Customers and the Public

Residential and commercial solar installers frequently work around homeowners, tenants, employees, customers, pedestrians, and other members of the public.

Work areas should be controlled to prevent unauthorized entry and exposure to:

• Falling objects.
• Ladders.
• Electrical hazards.
• Tools.
• Materials.
• Cranes and hoists.
• Vehicles.
• Open excavations.

Barricades, signs, controlled access, or other protective measures should be used as appropriate.

Driving and Fleet Safety

Solar contractors may operate pickups, vans, service vehicles, trailers, and trucks between multiple installation sites.

Driving procedures may address:

• Driver qualification.
• Seat-belt use.
• Distracted driving.
• Vehicle inspection.
• Trailer towing.
• Load securement.
• Backing.
• Parking.
• Accident reporting.
• Vehicle maintenance.

Solar panels, ladders, racking, tools, and other materials should be properly secured during transport.

Working Alone and Remote Solar Sites

Employees working at remote solar facilities or performing service activities alone may have limited access to immediate assistance.

Where applicable, procedures should address:

• Communication.
• Check-in procedures.
• Emergency contacts.
• Location information.
• First aid.
• Weather.
• Electrical hazards.
• Restricted activities that should not be performed alone.

The company’s Working Alone procedures should reflect the hazards and remoteness of the work.

Emergency Response

Emergency planning should reflect the solar installation and work location.

Plans should address as applicable:

• Falls and suspended-worker rescue.
• Electrical shock.
• Arc-flash injuries.
• Fire.
• Battery incidents.
• Heat illness.
• Severe weather.
• Equipment incidents.
• Utility emergencies.
• Emergency communication.
• Site access for responders.

Employees should understand how to summon assistance and communicate the location of the worksite.

Job Safety Analysis for Solar Installation

A Job Safety Analysis (JSA/JHA) can help solar contractors identify hazards and establish controls before work begins.

Solar-installation JSAs may address:

• Rooftop access.
• Solar panel installation.
• Panel lifting.
• Fall protection.
• Ladder use.
• Electrical installation.
• Inverter installation.
• Aerial-lift work.
• Crane and hoist operations.
• Battery installation.
• Excavation and trenching.
• Underground electrical work.
• Pile installation.
• Heavy-equipment operation.

The JSA should reflect the actual system, work location, equipment, weather, and site conditions rather than being treated as a generic checklist.

Additional Safety Programs for Solar Contractors

Not every solar contractor requires the same safety programs.

Depending on the company’s operations, additional programs may include:

• Aerial and Boom Lift Safety.
• Arc Flash / NFPA 70E.
• Battery and Energy Storage Safety.
• Cold Stress.
• Compressed Gas Cylinders.
• Crane Safety.
• Driving and Fleet Safety.
• Electrical Safety.
• Excavation and Trenching.
• Fall Protection.
• Fire Prevention.
• Forklift Safety.
• Hand and Power Tools.
• Hazard Communication.
• Hearing Conservation.
• Heat Stress Prevention.
• Heavy Equipment and Mobile Equipment.
• Ladder and Stairway Safety.
• Lockout/Tagout.
• Manual Lifting and Material Handling.
• Overhead Power Line Safety.
• Personal Protective Equipment.
• Pile Driving.
• Respiratory Protection.
• Rigging and Material Handling.
• Roof Safety.
• Scaffolding.
• Scissor Lift Safety.
• Severe Weather.
• Silica Exposure.
• Underground Utilities.
• Working Alone.
• Working Around the Public.
• Other programs applicable to the company’s solar operations.

Programs should be selected because they reasonably apply to the company’s work, equipment, employees, and workplace exposures.

Solar Installation Toolbox Talks

Toolbox talks can reinforce safe work practices and address hazards relevant to current solar installation activities.

Useful topics may include:

• Fall protection.
• Ladder safety.
• Roof edges and skylights.
• Electrical safety.
• Lockout/tagout.
• Panel lifting.
• Heat stress.
• Severe weather.
• Hand and power tools.
• Aerial lifts.
• PPE.
• Driving safety.

Toolbox talks supplement required safety training but do not replace training specifically required by applicable OSHA standards.

Solar Installation Safety Manual vs. Site-Specific Safety Plan

A Solar Installation Safety Manual establishes the company’s overall safety policies, programs, and procedures.

A Site-Specific Safety Plan (SSSP) applies applicable requirements to a particular solar installation or construction project.

For example, the company manual may contain Fall Protection, Electrical Safety, LOTO, Ladder Safety, Crane Safety, PPE, and other programs. Project-specific planning can then address the actual roof configuration, electrical system, equipment, access, fall hazards, material-staging areas, weather conditions, emergency arrangements, and other conditions unique to the installation.

The company safety manual therefore provides the foundation for project-specific solar safety planning.

Building a Solar Installation Safety Manual

A practical Solar Installation Safety Manual should reflect the work the company’s employees actually perform.

When determining which programs to include, consider:

• Residential rooftop solar.
• Commercial rooftop solar.
• Ground-mounted solar.
• Utility-scale solar.
• Photovoltaic electrical work.
• Grid interconnection.
• Battery energy storage.
• Roof access.
• Fall protection.
• Cranes and hoists.
• Aerial lifts.
• Excavation and trenching.
• Pile installation.
• Heavy equipment.
• Electrical hazards.
• Environmental conditions.
• Customer and public exposure.
• Applicable OSHA requirements.
• General contractor and customer requirements.
• Contractor-prequalification requirements.

Selecting programs according to actual operations produces a safety manual that addresses the contractor’s real hazards without filling the manual with unrelated safety programs.

Customized Safety Manuals for Solar Contractors

Solar installation contractors can request a customized Construction Safety Manual containing the Core Safety Programs and additional programs applicable to their rooftop, electrical, ground-mounted, utility-scale, battery-storage, and other solar operations.

Programs can be selected according to the company’s actual work so the manual addresses relevant solar installation hazards without including large numbers of unrelated safety programs.

Individual safety programs can also be selected when a solar contractor needs to add or update a particular program within an existing manual.